Troubleshooting Troubleshooting using error code Teode Valid from serial number Date Order number 815, 816 6070557- 2009-12-22 7510399-040 The first digit of the three-digit error code indicates the severity of the error and how the truck is affected/responds when the error occurs. Code number Error category/action taken n:0nn Caution. Generally an information code, No action to be taken on the truck. nein Warning. Some functions may be disabled or reduced. See the specific error code to see what action has been taken. n:2nn Error, All parts of the hydraulic system are disabled. See the specific error code to see what action has been taken. n:3nn Error. The truck is braked by the motor and/or the support arm brake and/or the parking brake until it ‘comes to a halt. It is not possible to drive. The steer- ing may be disabled if there is a steering error. To see what action has been taken, see the specific error code. n:4nn Error. The truck is braked by the motor brake until it stops. Once the truck has stopped, or after 5 sec- onds, the relays for the main power supply and key are switched off n:5nn Critical error. Main contactor and key relay opens. The error codes are subdivided into smaller categories based on the last two digits of the code (see below). Error code, type of error Code number :n00—n08 n:nt0—n19 Deseri fion Miscellaneous error codes. CAN-related error codes. n:n20-139 Error codes related to specific units. n:n40—n59 Error codes for short-circuited output data. n:n60—n79 Error codes for output data from open electrical circuits. n:n80—n99 Faulty signals from sensors.Troubleshooting Troubleshooting using error code Ordernumber Date Valid from serial number T-code 7510399-040 2009-12-22 6070557- 815,816 8.5.1 CID, warnings and errors Indica- | Cause Tip tor. 1,003 Slight firmware version incompati Update the truck software to the latest ity. available version. The firmware versions in the MCU and CID do not match. The MCU does not support some of the functions used by the CID, or vice versa. 1.004 | Incompatibility in the display Update the truck software to the latest firmware. available version, The firmware versions in the MCU and CID do not match, The MCU does not ‘support some of the functions used by the CID, or vice versa. 1,010 CAN 1 communication warning. 1. Check that CAN 1 is intact in terms of The CID CAN module has received too ate Se ia ciel contacts. many error messages 2. Disonnect the battery. Check that the resistance between [X41:3] and [X41:4] is 54 — 66 ohm. 3. Deactivate and disconnect LID and DHU. 1.120 LID sends an invalid status. Update the truck firmware to the latest The LID is blocked. available version. 7.121 | No message received from the LID. | 1. Check that CAN 1 is intact in terms of LID blocked. wiring harness, final resistance and contacts. 2. Disonnect the battery. Check that the resistance between [X41:3] and [X41:4] is 54 - 66 ohm. 3. Deactivate and disconnect LID. 4:412 LID communication warning. 1. Verify that CAN 1 is complete with re- The LID is blocked, gard to cabling, final resistor and ter- minals 2. Disconnect the battery. Verify that the resistor between [X41:3] and [X41:4] provides 54— 66 ohms. 3. Disable by changing parameter 1106 and disconnecting the LIDTroubleshooting Troubleshooting using error code Teode Valid from serial number Date Order number 815, 816 6070857- 2009-12-22 7510399-040 Indica- | Cause Tip tor. 7431] External +5 Vis ou 7. Disconnect the joysticks, buttons and ted area. sensors connected to [X505:1] one at a time and check ifthe error code dis- appears. 2. Check the CID's internal wiring har- ness. 3._ Replace the CID. 7500 | Software error Update the truck's software to the latest available version 1501 | GlD has detected an error in the Update the truck's software to the latest MCU's program execution. available version, 1.503 | Only one of the CID and the MCU is | 1. Log off and make the truck without in emergency driving mode. voltage for approx 1 minute. 2. Restart the truck and log in again 1504 | The software for CID and MCU are _| 1. Update the software for CID, MCU and not compatible. other units tothe latest available ver- Not possible to log in. sions. 2. Check that the software are compati- ble. 7:507 | GID and MGU firmware packages are | Update the truck software to the latest incompatible. available version The firmware versions in the MCU and CID do not match. The MCU does not support some of the functions used by the CID, or vice versa. 7:508 | LID and MCU firmware packages are | Update the truck software to the latest 2 incompatible. available version, 1:508 | The firmware versions in the MCU and LID do not match. The MCU does not support some of the functions used by the LID, or vice versa 1.510 | Communication error - GAN 1. 7. Check that CAN T is intact in terms of wiring hamess, final resistance and contacts 2. Disonnect the battery. Check that the resistance between [X41:3] and [X41:4] is 54-66 ohm, 3. Deactivate and disconnect LID, BHU and collision sensor. Activate and then connect them one by one to find out which unit gives rise to the communi- cation error.Order number 7510399-040 tor. Indica- Date 2009-12-22 6070557- Cause Valid from serial number Troubleshooting Troubleshooting using error code Tcode 815, 816 Tip 1512 ‘Communication disturbance — CAN 1. 7_ Check that CAN is intact in terms of wiring harness, final resistance and contacts. 2. Disonnect the battery. Check that the resistance between [X41:3] and [X41:4] is 54 —66 ohm 3, Deactivate and disconnect LID, DHU and collision sensor. Activate and then connect them one by one to find out which unit gives rise to the communi- cation error. 1.514 1.516 MCU or CID has not received a response within 70 ms via CANT. 1, Check that CAN 1 is intact in terms of, wiring harness, final resistance and contacts. 2. Disonnect the battery. Check that the resistance between [X41:3] and [X41:4] is 54-66 ohm 3. Deactivate and disconnect LID, DHU and collision sensor. Activate and then ‘connect them one by one to find out which unit gives rise to the communi- cation error, 1.520 Internal +5 Vis outside the permitted area. Replace the CID. 1.540 Key relay [K20] - Break in the control circuits 1. Check that there is no break in the key relay's coil 2, Check the contacts [X131] and [X504] the relationship between [K20:A1] — [X131:5] as well as [20:A2] — [x504:17]. 3. Replace the CID [A‘] 1.580 Key Relay [K20] — Contacts welded 1. Check the key relay’s function and that there is no relationship between [K20:1] and [20:2] 2. Check for the presence of a short cuit that may cause improper feeding of [X504:7], e.g. from [X504:16], [X504:17] and [X504:18}Troubleshooting Troubleshooting using error code Teode Valid from serial number Date Order number 815, 816 6070587- 2009-12-22 7510398-040 Indica- | Cause Tip tor. 7581 | Key relay [K20] does not close Check if the CID's input [X504:7] switches status when the key relay is used, CID's diagnostic screen 2, pos 20: 32] 1-8: ao1a9000 7 | 27462 Ooogo000 1?-24: 10@-- 25-32 If the input does not change status: + Check that fuse [F74] is complete. + Check the key relay’s function and that there is a relationship between [K20:1] and [K20:2] when the relay is drawn. + Check that conductor 26 from the key relay to the fuse box and conductor 28 from the fuse box to the CID input [X504: 7] are intact. + Replace the CID. If the input changes status: + Update the CID's software. + Replace the CID [A1].Troubleshooting Troubleshooting using error code Order number Date Valid from serial number T-eode 7510399-040 2009-12-22 6070557- 815,816 8.5.2 MCU and other warnings and errors Indica- | Cause Tip tor. 2,002 __| The MCU Is programmed using stand- | Download or adjust the parameters to cor- ard values for parameters. respond with the truck model and equip- ment. 2.003 | MCU memory error. 1. Backup the truck's parameters. Backup data, hour meter and errorlog | > Yadate to the latest software. may be affected 3. Check parameters and hour meter. 4. Copy the truck configuration from CID to MCU. 2,004 | Error in check sums of backup data. | 1. IfMCU or CID has been changed, Normally shown after replacing MCU or copy the truck configuration from the CID. MCU or CID unit which has not been replaced to the new unit 2. Backup the truck's parameters. 3. Update to the latest software. 4. Check parameters and hour meter. 2.005 | Hour meter reading to service=0. | Carry out service reset the S counter using TruckCom. 2.006 _| Full error log buffer. Shows that errors which would normally No indication, logged only. be logged in the error log may have been lost. 2.007 | MCU internal memory full 1. Report the error to the manufacturer. 2. Restart the truck. 3. Ifthe error remains, update the truck firmware to the latest available ver- sion. 2:008 | Application time. Set when the application (20 ms) takes No indication, logged only. longer than 17 ms. 1, Fix the error code generated in direct relation with this error code. 2. Report the fault to the manufacturer. 2.009 | Tick time. No indication, logged only. Set when tick time (1.25 ms) takes longer than 1.10 ms. 1. Fix the error code generated in direct relation with this error code. 2. Report the fault to the manufacturer.Troubleshooting Troubleshooting using error code Teode 815, 816 Indica- tor. Valid from serial number 6070557- Cause Date 2009-12-22 Order number 7510399-040 Tip 2010 2.011 ‘Communication disturbance - CAN 1 MCU has received too many incorrect telegrams. Communication disturbance - CAN2. MCU has received too many incorrect telegrams. 7. Ifthe CAN keyis connected: Try using a CAN-Key with a later production date. 2. Check that CAN 1 is intact in terms of wiring hamess, final resistance and contacts. 3. Disonnect the battery. Check that the resistance between [X41:3] and [X41:4] is 54-66 ohm. 4. Deactivate and disconnect LID, BHU and collision sensor. Activate and then connect them one by one to find out which unit gives rise to the communi- cation error. 1. Check that CAN 2 is intact in terms of wiring hamess, final resistance and contacts. 2. Disonnect the battery. Check that the resistance between [X130:8] and [X130:22] is $4 - 66 ohm. 3. Disconnect EPS, ACT and ACH. Then connect them one by one to find out which unit gives rise to the communi- cation error. 2101 Truck type incorrect. Factory parameters have not been entered, Use TruckCom to save the parameter val- ues, If the MCU was replaced: + Enter the truck's parameter list. + Check parameter "1001 - Truck type’, if itis incorrect all parameters must be verified + Copy the Truck Configuration from the CID to the MCU 2:102 Height pre-selection — Stop hi error. 1. Lifting: Inspect/adjust parameters 371, 373 and 375. 2. Lowering: Inspect the free-lowering and main lowering valve calibration. Inspect/adjust parameters 372, 374 and 376. 3. Adjust parameter 377Troubleshooting Troubleshooting using error code Order number Date Valid from serial number T-eode 7510399-040 2009-12-22 6070557- 815,816 Indica- | Cause Tip tor. 2:103__| Lifting height limiting. Ifthe truck Is equipped with height indica Lifting height limiting is activated and _| tion, activate this using factory parameter height measurement is deactivated. 1009 = 1. If the truck does not have height indica- tion, deactivate the lifting height limiting using parameter 1107 = 0. 2:104 | Height pre-selection Ifthe truck features height indication, ena- Height pre-selection is enabled and ble this with factor parameter 1009 = 1 height measurement is disabled If the truck does not feature height indica- tion, disable height pre-selection with parameter 1103 = 0 2:105 | More than 80 % difference between | Check parameter 113. the MCU's measured power con- B-version: 280 sumption and the measure consump- | E-version: 335 n of the ACTIACH (>2 sek @ >200 A). No reduction/blocking of the truck's func- tions. 2:106 | Collision locking. if parameter 112 = 0: Use the special PIN Acolision value exceeding what has_| code to reset the collision sensor. been input via parameters 110 and 111 | If parameter 112 = 1: Restart the truck to has been detected, teset the collision sensor. The truck can only be driven at reduced speed. 2:141 | Digital output DO9 — short circuit 1. Check that conductor X131:9, conduc- tor 33, has not short circuited with con- ductor 27 2. Check that fan G3 has not short circuited. 3. Check that cables and contacts are undamaged 4, Check output DOS via the CID's diag- nostic screen 5, pos 9: £2] 4-8: oo1ocoo1 5] oe @poooacoTroubleshooting Troubleshooting using error code Teode Valid from serial number Date Order number 815,816 6070557- 2009-12-22 7510399-040 Indica- | Cause Tip tor. 2:161 | Digital output DOS — break. 7. Check that there is no break in con- ductor X131:9, conductor 33 and con- ductor 27 leading to fan G3. 2. Check that cables and contacts are undamaged 3. Check output DOS via the CID's diag- nostic screen 5, pos 9: | 1-8: oore002 5 | 26 @pooo000 25-32 23180 | No contact with the shock sensor. _| 1._ ifthe truckis not equipped with a coli sion sensor, set parameter 110 = 0 and 111 2. Check that cables and contacts are undamaged 3. Replace [B90] 2:401 _| Internal programme error 1. Report the error to the manufacturer. Restart the truck If the error remains, update the truck firmware to the latest available ver- sion. 2:403 | Permitted time for reading the ana- | 1. Report the error to the manufacturer. logue 2. Restart the truck signal exceeded. 3. Ifthe error remains, update the truck firmware to the latest available ver- sion. 2:420 | Battery voltage under 33.6 V. 1. Check the battery voltage. 2. Check that the battery cable is undam- aged and free from oxidation. 3. Check that the voltage between [130:19] and [X130:32] corresponds to the measured battery voltage. 4. Replace the MCUOrder number 7510399-040 Indica- tor. Date 2009-12-22 6070557- Cause Valid from serial number Troubleshooting Troubleshooting using error code Tcode 815, 816 Tip 2421 2:431 2:432 Battery voltage over 72 V. +5 V for external sensors under +4.9 v. +5 V for external sensors over +5.1 V. 7. Ifthe error code occurs in association with strong motor braking directly after charging: Log outilog in. 2. Ifthe error code occurs during motor braking during normal driving: Check all power cabling between the battery and transistor regulator for breaks, poorly tightened screws/nuts and oxidation. Ifthe error code is shown at the same time as error code 2:433, the troubleshooting must begin with this, 1. Make sure that no short circuit or other high load is present in the sensor (B4], safety pedal or pedal unit for speed and braking. 2. Check the wiring hamess to the com- ponents above. 3. Replace the MCU and check the func- tion of the sensor [B4], safety pedal and pedal unit for speed and braking. 1. Check that there is no short circuit present in conductor 55 and any con- ductor with higher voltage than 5 V, eg. battery voltage, 2. Check the function of = Sensor [B4] ~ Safety pedal — Pedal unit for speed and brakes. 3._ Replace the MCU. 2:433 +15 V for external sensors under +12 v. 1. Check that there is no short circuit or high load in sensors [B18] and [B19] 2. Check the wiring hamess to the com- ponents above. 3. replace the MCU and check the func- tion of sensors [B18] and [B19]Troubleshooting Troubleshooting using error code Teode Valid from serial number Date Order number 815, 816 6070587- 2009-12-22 7510399-040 Indica- | Cause Tip tor. 2434] #15 V for external sensors over #165 | 1. Check hat there isno shor circu v. present in conductor 29 and any con- ductor with higher voltage than 15 V, e.g. battery voltage. 2. Check the function of sensors [B18] and [B19] 3. Replace the MCU. 2435 | Internal 47.5 V under 47 V. Replace the MCU. 2:436__ | Internal +7.5 V over #8 V. Replace the MCU 2:501 | Check sum error, parameters 7. Restart the truck 2._ Replace the MCU 2502 _| Serious firmware error, MCU. 7. Report the errorto the manufacturer, 2. Restart the truck, 3. Ifthe error remains, update the truck firmware to the latest available ver- sion, 2:503_| error in check sum, factory parame- | 1. If MCU or CID has been changed, ters. copy the truck configuration from the Normally shown after replacing MCU or | MCU or CID unit which has not been cD. replaced to the new unit 2. Backup the truck's parameters. 3. Update to the latest software, 4, Check factory parameters. 2:504 | Only one of the CID and the MCU is in | 1. Log off and make the truck without emergency driving mode. voltage for approx 1 minute. 2. Restart the truck and log in again 2:505 | MCU has detected an error inthe | Update the truck's software to the latest CID's program execution. available version, 2507 | Truck operation disabled, Contact the local representative of the manufacturer, or the manufacturer Seo ele coker directly, to reactivate the truck,Order number 7510399-040 Indica- tor. Troubleshooting Troubleshooting using error code Date Valid from serial number T-code 2009-12-22 6070587- 815, 816 Cause Tip 2510 2511 2612 Initialisation error — CAN 1. Initialisation error — CAN 2. ‘Communication disturbance — CAN 1. 1. Check that CAN 1 is intact in terms of wiring hamess, final resistance and contacts. 2. Disonnect the battery. Check that the resistance between [X41:3] and [X41:4] is 54-66 ohm 3, Deactivate, disconnect and reconnect the units from CAN1 individually to find the device giving rise to the initialisa tion error. 1. Check that CAN 2is intact in terms of wiring harness, final resistance and contacts. 2. Disonnect the battery. Check that the resistance between [X130:8] and [X130:22] is 54 — 66 ohm. 3, Deactivate, disconnect and reconnect the units from CAN2 individually to find the device giving rise to the initialisa- tion error. 1. Check that CAN 1 is intact in terms of wiring hamess, final resistance and contacts. 2. Disonnect the battery. Check that the resistance between [X41:3] and [X41:4] is 54-66 ohm 3, Deactivate and disconnect LID, DHU and collision sensor. Activate and then ‘connect them one by one to find out which unit gives rise to the communi- cation error, 2513 ‘Communication disturbance — CAN 2. 1. Check that CAN 2s intact in terms of wiring hamess, final resistance and contacts, 2. Disonnect the battery. Check that the resistance between [X130:8] and [X130:22] is 54 — 66 ohm,Troubleshooting Troubleshooting using error code Teode Valid from serial number Date Order number 815, 816 6070587- 2009-12-22 7510398-040 Indica- | Cause Tip tor. 2514 | Login error — DHU. Check that parameter 503 corresponds to the truck's equipment: 4. Check that itis possible to connect TruckCom to the DHU. Ifitis possible to connect them, check the DHU's configuration, 2. Check that the DHU's green LED is lt. If the LED is not lit: Check the DHU's feed voltage: The battery voltage be- tween [A82:1] and [A82:8] If there is a battery voltage: Replace the DHU. 3. Check that CAN 1 is intact in terms of wiring hamess, final resistance and contacts: Disonnect the battery. Check that the resistance between [A82:2] and [A82:3] is 54 - 66 ohm 2:523 | Discharge current over 800 A. Check parameter 113: B-version: 280 E-version: 335 2:531__| Internal +5 V under +4.9 V. Replace the MCU. 2:532 _| Internal +5 V over +5.5 V. Replace the MCU. 2:533 _| Internal +15 V under +14.25 V. Replace the MCU. 2534 _| Internal +15 V over #15.75 V. Replace the MCU. 2:537 | Internal feed supply for digital outputs | Replace the MCU. under 9.7 V. 2:538 | Internal feed supply for digital outputs | Replace the MCU. over 12V. 2:540 | Short circuit in output for main con- | 7. Check that the main contactor's coil tactor [Q10]. has not short circuited, 2. Check that there is no short circuit in connection [X131:7], cable 31. 3. Replace the MCU and check the main contactors function. 2:555 _| Valid time for startup exceeded. Check that fuse [F73] is complete. 2. Check that the wiring harness and contacts are intact and correctly at- tached.Troubleshooting Troubleshooting using error code Ordernumber Date Valid from serial number T-code 7510399-040 2009-12-22 6070557- 815,816 Indica- | Cause Tip tor. 2556 | Valid T__Tum off the truck by disconnecting the battery. 2. Restart the truck and log in. 2:560 | Main contactor [Q10] output inter- | 1. Verify that the main contactor coil is rupted. not interrupted 2. Verify that there is no interruption be- tween terminal [Q10:A2] and [X131:7], cable 31 3. Verify that the battery voltage is present between [Q10:A1] and B-. If there is no battery voltage. + Check that the emergency switch is not depressed, + Verify that the F60 fuse is not defec- tive 4, Log in in the emergency travel mode to reset the main contactor status. 5. Inspect the main contactor for correct operation. Replace the main contactor 7. Replace the MCU 2:580 | Main contactor [Q10] - Terminals 1. Inspect the main contactor for correct welded operation and that there is no connec- tion between [10:1] and [10:2] 2. Verify that there is no short-circuit that could cause incorrect power supply to (13135). 3. Loginin the emergency travel mode to reset the main contactor status. 2:581 | Main contactor [10] — A 1. Inspect the fuse [F771] detected by MCU. 2. Inspect the main contactor for correct operation and that there is connection between [Q10:1] and [Q10:2]. 3. Verify that there is no interruption in conductor 8 between the main contac- tor and the fuse panel as well as in conductor 23 between the fuse panel and [X131:15} 4, Loginin the emergency travel mode to reset the main contactor status.Troubleshooting Troubleshooting using error code Teode Valid from serial number Date Order number 815,816 6070557- 2009-12-22 7510399-040 Indica- | Cause Tip tor. 2:582 _ | Key relay input status Is not the same | 1, Inspect the fuse [F74] between the MCU and CID 2. Verify that conductor 28 from the fuse {F74] to the MCU input [131:6] is in- tact. 3. Verify that conductor 28 from the fuse [F74] to the CID input [X504:7] is in- tact,Troubleshooting Troubleshooting using error code Ordernumber Date Valid from serial number T-code 7510399-040 2009-12-22 6070557- 815,816 8.5.3 Drive system error Indica- | Cause Tip tor. 3:080 Safety pedal actuated for more than Check input A6 via the CID diagnostic dis- 20 minutes. play 3, pos 6 a When the pedal is pressed down, the sig- nal should be approx. 3.5 V and when released the signal should be approx. 15V. If the signal does not change: + Verify that the cabling and terminals are intact + Replace the safety pedal [B31]. + Replace the MCU. Ifthe signal does change: + Log out and disconnect the battery for approx. 1 minute. + Reconnect the battery, log in and check whether the error indication has disap- peared. + Update the truck firmware to the latest available version. + Replace the MCU.Troubleshooting Troubleshooting using error code Teode Valid from serial number Date Order number 815, 816 6070587- 2009-12-22 7510399-040 Indica- | Cause Tip tor. 3.081 | Seat switch actuated for more than | Check input DI12 via the CID diagnostic 20 minutes. display 4, pos 12: S| 010110 4 oog@Loo0 oooL1000 :O-- When the seat is occupied, the signal should be 1’ and when unoccupied it should be ‘0’ If the signal does not change: + Verify that the cabling and terminals are intact. + Replace the seat switch [B49], + Replace the MCU. Ifthe signal does change: + Log out and disconnect the battery for approx. 1 minute. + Reconnect the battery, log in and check whether the error indication has disap- peared + Update the truck firmware to the latest available version. + Replace the MCU. 3:142 | Short circuit in the left support arm | 1. Check that the resistance of the brake bral coll [16] is between 44 and 52 ohm. Max travel speed is limited to 9 kmih. 3:143 | Short circuit in the right support arm | 1. Check that the resistance of the brake brake. coll 17] is between 44 and 52 ohm. Max travel speed is limited to 9 kmh. 3:162 | Breakin the left support arm brake, | 1. Check thal the resistance of the brake Max travel speed is limited to 9 km/h, coil (Q16] is between 44 and 52 ohm. 3163 | Breakin the right support arm brake. | 1. Check that the resistance of the brake Max travel speed is limited to 9 km/h. coil (Q17] is between 44 and 52 ohm.Order number 7510399-040 Indica- tor. Date 2009-12-22 6070557- Cause Valid from serial number Troubleshooting Troubleshooting using error code Tcode 815, 816 Tip 3180 3:30 ‘Safety pedal output voltage incorrect. Faulty reversing brake. The truck is braked using the mechani- cal brake and driving is disabled, Verify that the safety pedal output volage is within 1.5 V to 3.5 V. CID diagnostic dis- play 3, pos 6: aI 3 10:51.21 If the output voltage is outside the lim- its: + Verify that the voltage is between 4.5 V and 5.5 V between [B31:1] and [B31:3]. + Inspect [X130:31], conductor 84 for in- terruptions, short-circuits or incorrect power supply. If the output voltage is within the limits, but does not change when the pedal is operated: + Replace the pedal [B31]. + Update the truck firmware to the latest available version. + Replace the MCU. 1. Check the battery charge status. ifthe battery is fully charged when the motor brakes strongly, this may be the cause of the error. 2. Check the battery cables and their connections. 3. Check the three phase connections between the motor and the ACT. 4, Replace ACT. 3:305 Motor temperatur over 180°C. The truck is braked by the motor brake until it stops. Cheek that the resistance in the drive motor’s temperature sensor is be- tween 550 ohms and 650 ohms. At 150°C the resistance should be 600 ohm, 2. Check that the fan for the motor com- partment works and that the ventilation ‘openings are not blocked 3, Check that the drive motor is not dam- aged.Troubleshooting Troubleshooting using error code Teode Valid from serial number 815, 816 6070557- Indica- | Cause tor. Date Order number 2009-12-22 7510399-040 Tip 3:314 | The MCU or ACT have not responded - | via CAN2 within 70 ms. 3:316 | The truck is braked by the motor brake unti it stops. 3:320 | ACT — Voltage for motor supply out- = side specified limits. 3:322 _ | The truck is braked by the motor brake Until it stops. 7. Check fuse [F73]. 2. Check that CAN 2 is intact in terms of wiring hamess, final resistance and contacts. Disonnect the battery. Check that the resistance between [X130:8] and [X130:22] is 54 — 66 ohm, 3. Check that the ACT's green LED is it constantly If the LED is not lit: + Check that the ACT has a supply volt- age of 48 V between [K1:3] and [B+] + Replace ACT. If the LED is lit: + Replace ACT. Check 4, Fuse F71 2 F4 3. That the main contactor {Q10] is closed and that the contacts are not burned. 4, That the wiring hamess between the battery and the ACT are complete and not oxidised. 3:323 | Overcurrent - ACT. The truck is braked by the motor brake until it stops. Check 1. That the battery voltage is correct when connected to the ACT. 2. That the battery wiring hamess is un- damaged and there is no relationship between B+ and B-. 3. That the motor cables are undamaged and there is no relationship between them or with Be 4. The motor windings’ resistance to the motor yoke, there should be no rela- tionship. 5. Test using a new motor controller. If the error persists, the fault is probably an internal motor problem. Replace the motor and refit the old controller.Troubleshooting Troubleshooting using error code Order number Date Valid from serial number T-eode 7510399-040 2009-12-22 6070557- 815,816 Indica- | Cause Tip tor. 3325 | The ACT's cooling element is over | Check that the cooling fan for the ACT 125°C. and ACH is working normally. CID Service The truck is braked by the motor brake | function: until it stops. If the fan is working normally: + Clean the ACT's cooling element and associated ducts. Ifthe error returns the fault is probably an internal ACT prob- tem. If the fan does not work normally: + Ifthere is not 48 V between [G3:1] and {G3:2]: Check the wiring harness and the MCU. + Ifthere is not 48 V between [G3:1] and [3:2]: Check the fan 3:328 | Short circuit in the ACT, the drive Check motor or the motor cables. 4. That the motor cables are undamaged he tuck Is braked by the motor brake and there is no short circuit between unt it stops. them or with B-. 2. The motor windings’ resistance to the motor yoke, there should be no rela- tionship, 3, Test using a new motor controller. If the error persists, the fault is probably an internal motor problem. Replace the motor and refit the old controller. 3:329__| Measurement/Calibration error in the | 1. Log off and make the truck without ACT's current measurement. voltage for at least 1 minute. The trucks braked by the motor brak® | > Restart the ruck and og in again, SoS If the fault persists: + Replace ACT.Troubleshooting Troubleshooting using error code T-code Valid from serial number Date Order number 815,816 6070557- 2009-12-22 7510399-040 Indica- | Cause Tip tor. 3:331 | The ACT's internal 5 volts is outside | Check the specified limits. . The truck is braked by the motor brake Fuse F73 until it stops + The battery voltage (ACT K1:9] and B- If the voltage deviates from the battery voltage: + Check that cable 27, between the fuse box and the ACT, is undamaged and that the connections are not oxidised. If the voltage is the same as the battery voltage: + Replace ACT. 3:333__| The ACT's internal 15 volts Is outside | Check the specified limits . The truck is braked by the motor brake peel) until it stops, + The battery voltage (ACT K1:9] and B- If the voltage deviates from the battery voltage: + Check that cable 27, between the fuse box and the ACT, is undamaged and that the connections are not oxidised If the voltage is the same as the battery voltage: + Replace ACT. 3:380 | Break or short circuit in the speed __| Loosen the sensor and remeasure [B11:1] sensor [B11]. Max travel speed is reduced to 10.5km/ h and [B11:4], '1' = + and °a' = -. The resist- ance should be approx 160 kohm. If the resistance measurement sug- gests a breakishort circuit in the sen- sor: + Replace the sensor. If the resistance measurement excludes a break/short circuit: + Check conductors “10” and "11", [B11:1)(K1:11] and [811:4)/[K 1:6), for any break/short circuit. If the conductors are undamaged: + Replace ACT.Troubleshooting Troubleshooting using error code Order number Date Valid from serial number T-eode 7510399-040 2009-12-22 6070557- 815,816 Indica- | Cause Tip tor. 3385 __| The voltage from the accelerator Check that the accelerator pedals output pedal [B32] is outside the specified Driving is blocked and the truck is braked to a stop with the motor brake, Voltage is between 0.25 V to 4.75 V. CID's diagnostic screen 3, pos 5: aI 1.52 0.50 4.50 0.00 If the output voltage is outside these + Check that the voltage is between 4.5 V and 5.5 V between [B32:6] and [B32:1] + Check that there is no break, short cir- cuit or incorrect feed to [X130:17], con- ductor 87/GY. If the output voltage is within limits, but that changes when the pedal is affected: + Replace the pedal [B32] + Download new software to the MCU. If this involves an update, the software for the CID must also be changed. + Replace MCU.Troubleshooting Troubleshooting using error code Teode Valid from serial number Date Order number 815, 816 6070587- 2009-12-22 7510398-040 Indica- | Cause Tip tor. 3:387 | The voltage from the brake pedal Check that the brake pedal's signal 1 out- [B32], signal 1, is outside the speci- Ss. Driving is blocked and the truck is braked to a stop with the motor brake. put voltage is between 0,25 V to 4.75 V. CID's diagnostic screen 3, pos 7: al : 0,00 3.14 0.00 Or? 5: 0.50 If the output voltage is outside these Ss: + Check that the voltage is between 4.5 V and 5.5 V between [B32:6] and [32:1] + Check that there is no break, short cir- cuit or incorrect feed to [X130:4], con- ductor 85/WH. Ifthe output voltage is within limits, but that changes when the pedal affected: + Replace the pedal [B32] + Download new software to the MCU. If /olves an update, the software for the CID must also be changed + Replace MCU.Troubleshooting Troubleshooting using error code Order number Date Valid from serial number T-code 7510399-040 2009-12-22 6070557- 815, 816 Indica- | Cause Tip tor. 3388 | The voltage from the brake pedal Check that the brake pedals signal 2 out- [B32], signal 2, is outside the speci- fied limits. Driving is blocked and the truck is braked to a stop with the motor brake, put voltage is between 0.25 V to 4.75 V. CID's diagnostic screen 3, pos 8: oft: 9.00 1.52 3.14 0.50 2 |3: 0.00 4.50 a.77 7.00 520.50 10:s1.21 If the output voltage is outside these + Check that the voltage is between 4.5 V and 5.5 V between [B32:6] and [B32:1] + Check that there is no break, short cir- cuit or incorrect feed to [X130:18], con- ductor 86/8K. If the output voltage is within limits, but that changes when the pedal is affected: + Replace the pedal [B32] + Download new software to the MCU. If this involves an update, the software for the CID must also be changed. + Replace MCU.Troubleshooting Troubleshooting using error code Teode Valid from serial number Date Order number 815, 816 6070587- 2009-12-22 7510398-040 Indica- | Cause Tip tor. 3:389 | Too large discrepancy between both | Check that both the brake pedal signals" brake pedal signals. Driving is blocked and the truck is braked to a stop with the motor brake. output voltages follow each other and that one is inverse to the other, ™ . ” Ruy ‘apos) V = brake peda's output voltage, pos = Brake pedal depression The CID's diagnostic screen 3, pos 7 and 8 a 2 If the output voltage does not change normally: + Check that the voltage is between 4.5 V and 5.5 V between [B32:6] and [32:1], + Check that there is no poor relationship or faulty supply of [X130:4], conductor 85/WH and [X130:18], conductor 86/ BK. + Replace the pedal [B32]. Ifthe output voltage changes normally: + Download new software to the MCU. If this involves an update, the software for the CID must also be changed. + Replace MCUOrder number 7510399-040 Indica- tor. Date 2009-12-22 Cause Valid from serial number 6070557- Troubleshooting Troubleshooting using error code Tcode 815, 816 Tip 3:390 3:500 Voltage from the travel direction selector [B36] is outside the indicated Truck travel disabled and truck brakes to standstill using the motor brake. Unknown ACT error. Verify that the travel direction selector out- put voltage is within 0.25 V to 4.75 V when the selector is moved between its end positions. CID diagnostic display 1, pos 6: If the output voltage is outside the lim- its: + Verify that the voltage is between 4.5 V and 5.5 V between [A61:1] and [A6:4], + Inspect [X505:4], conductor 94/GY for interruptions, short-circuits or incorrect power supply. Ifthe output voltage is the limits, but does not change when the selector is operated: + Replace the A6 logic card including the sensor. + Update the truck firmware to the latest, available version. + Replace the MCU. 1. Update the truck firmware to the latest available version. 2. Replace the ACT. 3:520 ‘ACT start up error. Check that the ACT's green LED is lit con- stantly Ifthe LED is not lit: + Check fuse [F73] + Check that the ACT has a supply volt- age of 48 V between [K1:9] and [B-]. + Replace ACT. Ifthe LED is lit: + Replace ACT. + Check that CAN 2s intact in terms of wiring hamess, final resistance and contacts, Disonnect the battery. Check that the resistance between [X130:8] and [X130:22] is 64 — 66 ohm.